System for hanging doors



Dec. 27, 1960 ZERN SYSTEM FOR HANGING DOORS 5 Sheets-Sheet 1 Filed Feb. 13, 1956 I Dec. 27, 1960 w. B. ZERN svs'rzu FOR HANGING DOORS 5 Sheets-Sheet 2 Filed Feb. 15, 1956 Dec. 27, 1960 w. B. ZERN 2,966,131

SYSTEM FOR HANGING DOORS Filed Feb. 13, 1956 5 Sheets-Sheet 3 Fig.5

Dec. 27, 1960 w. B. ZERN SYSTEM FOR HANGING nooas 5 Sheets-Sheet 4 Filed Feb. 13, 1956 Dec. 27, 1960 w. B. ZERN SYSTEM FOR HANGING DOORS 5 Sheets-Sheet 5 Filed Feb. 13, 1956 United States Patent SYSTEM FOR HANGING DOORS Warren B. Zern, King and Franklin Sts., Pottstown, Pa.

Filed Feb. 13, 1956, Ser. No. 564,945

18 Claims. (Cl. 144-144} This invention relates to methods of and apparatus for preparing doors for hanging and has for an object the provision of a door sizing system which will enable a workman to cut and plane a new door to its proper size and shape and to install the hinges and lock at the proper locations so that the door will hang and operate perfectly when it is completed. The novel door sizing system enables a workman to custom-fit each door to its frame quickly and accurately and to maintain uniform predetermined tolerance and clearances as to all doors. The novel door sizing system enables even a relatively inexperienced Workman to provide better-fitting doors than is possible even by a skilled carpenter fitting the doors by hand, and such improved results are obtained in substantially less time.

This invention is applicable to custom-fitting doors to previously erected door frames and is particularly applicable to customfitting doors to frames comprising metal jambs. It is the practice today in constructing many large buildings such as schools, oifice buildings, hospitals, and the like, to employ metal door frames known in the trade as steel bucks. These steel bucks are put in place as the building is being erected, and the buck or jack to which the hinges are to be applied is previously provided with hinge seat recesses. To fit the door to the frame, there is provided in accordance with the present invention an adjustable gauge for measuring the width and contour of the door receiving opening in the frame and maintaining the measured relationship. There is also provided an adjustable support for first receiving the adjustable gauge and then the door, the support being adjustable in relation to the width of the door receiving opening as determined by the adjustable gauge. The support is provided with means for guiding a cutting tool along an edge of the door to decrease its width by an amount predetermined by the adjustable gauge.

Further in accordance with the invention there is provided in the system a second adjustable gauge for gauging the location of the hinge receiving openings in the door frame, said second adjustable gauge also being adapted to position template assemblies lengthwise of the hinge receiving edge of the door while it is held by the support preparatory to cutting hinge seats in that edge of the door.

The various components of the novel system also embody novel features which contribute to the improved results obtained with the system, as will hereinafter be described in detail.

For a more detailed disclosure of the invention and for further objects and advantages thereof, reference is to be had to the following description taken in conjunction with the accompanying drawings in which:

Fig. 1 is an elevational view of a door frame gauge positioned on a sizing device in accordance with the invention;

Fig. 1A is an enlarged sectional view taken along the lines 1A--1A in Fig. 1;

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Fig. 1B is an exploded view on enlarged scale of parts shown in Fig. 1;

Fig. 2 is a view taken along the lines 22 in Fig. 1;

Fig. 3 is an elevational view of the novel door frame gauge;

Fig. 4 is a perspective view on enlarged scale of part of the novel door frame gauge shown in Fig. 3;

Fig. 5 is a view on enlarged scale taken from the righthand end of Fig. 3;

Fig. 6 is an elevational view of the sizing device shown in Fig. 1 but with the door frame gauge removed and replaced by a door and a plane on the door;

Fig. 7 is a perspective view on enlarged scale of a modification of the adjustable supports on the sizing device;

Fig. 8 is a rear elevation on enlarged scale of the plane.

shown in Fig. 6 which embodies features of the present invention;

Fig. 9 is an end view of the plane taken from the righthand side in Fig. 8;

Fig. 10 is a perspective view of a guide shoe for the plane shown in Figs. 8 and 9;

Fig. 11 is a perspective view of an adjustable guide for the plane shown in Figs. 8 and 9;

Fig. 12 is a top plan view of the novel hinge seat gauge of Fig. 13;

Fig. 13 is a fractional front elevation of a door on the sizing device with templates adjustably spaced along the door by the novel hinge seat gauge means preparatory to routing hinge seats in the edge of the door; and

Fig. 14 is a fractional view of the hinge seat gauge in relation to the head jamb and a hinge seat on the door frame.

Referring to the drawings, there is shown apparatus for sizing a door preparatory to hanging it in a door frame. Such apparatus is useful in aiding the workman in both cutting and planing a new door to its proper size and shape and also to enable him to install the hinges and the lock at the proper locations so that the door will hang perfectly when completed. In Figs. 1 and 3 there is shown an adjustable door frame gauge 16 for gauging the contour of the door frame opening. The gauge 10 includes an elongated member 11 corresponding in length to the length of the door and two parallel end members 12 and 13 which project perpendicularly from the opposite ends of member 11. The members 11, 12 and 13 preferably are formed of a light weight material such, for example, as aluminum, in order that the overall weight of the gauge 10 will be relatively light and easily handled by the operator. In one specific embodiment the gauge 10 was constructed with members 11, 12 and 13 formed from hollow aluminum tubing having a rectangular cross-sectional area of approximately 1 inch by 2 inches. This construction provided a light weight gauge and at the same time the required rigidity to maintain the parts in predetermined relation to each other. The end members 12 and 13 are connected to the opposite ends of member 11 in any suitable manner such, for example, as by welding, and the required right angular relationship between the member 11 and members 12 and 13 is maintained by additional angularly disposed aluminum tubing members 14 and 15 respectively, Fig. 3. To provide further rigidity to the frame, there is provided a solid aluminum rod member 16 which extends between the angular members 14 and 15 and along the elongated member 11, the rod member 16 being joined to member 11 near the middle by cross pieces 17 and 18. The cross pieces 17 and 18 preferably are solid rod members the same as member 16, and in a specific embodiment were aluminum rods approximately inch in diameter.

The elongated member 11 is provided at each of its ends along one of its edges with T-shaped locating blocks including members 25} and 21 disposed at right angles to each other. The members 20, 26 are adapted to be placed against the side of a jamb adjacent the top and bottom of a door frame opening with members 21, 21 disposed adjacent the edge of the jamb at corresponding locations, as hereinafter to be described.

When the gauge 19 is placed in a door frame, member 11 will be in a vertical position with the end members disposed horizontally. End member 12 is adapted to be disposed at the head end of the door frame opening during the gauging operation and is provided with a telescoping member 23 adapted to slide within the member 12 and to extend from the end thereof opposite the T-shaped locating member at the head end of elongated member 11. The telescoping member 23 is locked in place with respect to end member 12 by suitable means such as screws 24, 24 extending into member 12. The combined lengths of members 12 and 23 may be adjusted to gauge door frame openings of different widths. The outer end of member 23 is provided with a micrometer adjusting member 25, the outer end of which is adapted to engage the top end of the opposite side of the jamb of the door opening from that engaged by the corresponding T-shaped locating block. The member 25, after it is adjusted to the width of the top of the door opening, is locked in position by suitable means such as a thumb screw 25a.

As thus far described, the arm or end member 13 disposed at the opposite end of elongated member 11 for gauging the width of the bottom of the door frame opening is constructed in similar manner to end member 12 and includes members 23, 24, 25' and 25a corresponding to members 23, 24, 25 and 25a, all adjusted in similar manner.

To provide further rigidity for arm 12 which is the gauge arm for the top of the door frame opening, there is provided a telescoping arrangement including an outer member 27 and inner member 28 adapted to be adjustably locked together by means of a screw 29 for interconnecting member 23 with member 16. Since arm 13 is adapted for use at the bottom of the door frame opening only to gauge wi th, it is not necessary that it be supported quite so rigidly as the arm 12 which is used at the top of the door frame opening to check squareness as well as width and which is surrounded on all three sides by the door frame. The telescoping member 23 is further provided with a spring biased plunger 31 which is disposed near the adjustable member 25 and in parallel relation with the locating surface of member 2!) carried by the head end of elongated member 11. The spring biased plunger 31 is carried in a housing 32 and is adapted to be held in retracted position by suitable means such as a thumb screw 33. When thumb screw 33 is released, the plunger 31 will be biased to an outward position under the influence of a spring (not shown) in housing 32, as later to be described. This will check the squareness at the top of the door.

As may be seen in Fig. 3, the elongated member 11 may be formed in two sections separated by an intermediate section 1111. The intermediate section 11a is adapted to carry adjustable locating devices 35 and 36, device 35 being shown on enlarged scale in Fig. 4. The devices 35 and 36 enable the workman to gauge the contour of the door frame opening in manner now to be described.

To gauge the door frame opening, the workman first adjusts the over-all length of the gauge 10 to a length somewhat greater than the length of the door to be hung in the door frame opening. This may be done by adjusting the telescoping member 38 which extends from the bottom of the gauge and is adjustably locked to member 11 in suitable manner as by screws 40, 40. The outer end of member 38 is preferably provided with a spring biased extension 39 for engaging the floor at the bottom of the door frame opening and holding the locating surface of member 22 against the head jamb. After the gauge 10 has been adjusted to the required length, the workman places the gauge vertically in the door frame opening with elongated member 11 adjacent one jamb and presses the locating members 20 and 21 against the corresponding edges along a corner of the jamb. With both the upper and lower T-shaped locating blocks against the corner of the jamb, the operator then adjusts one of the locating devices 35, 36 against the jamb and locks it in position. One of the locating devices 35, 36 is used to gauge an intermediate point of the hinge receiving jamb, and the other locating device is used to gauge the intermediate point of the lock receiving jamb.

The locating devices 35, 36 are disposed on opposite sides of the gauge 10 as may be seen in Fig. 3. The device 36 is adapted to be used with the locating angles formed by the adjacent perpendicular surfaces of the T- shaped blocks on that side of the gauge, and the locating device 35 is adapted to be used with the locating angles formed by the adjacent perpendicular surfaces of the T- shaped blocks on its sides of the gauge 10. More particularly, when the gauge 10 is disposed to the right of the operator in gauging a door frame opening, the locating device 36 is employed along with the angle formed by members 29 and 21 at the right-hand side as shown in Fig. 5. When the other side jamb of the door frame opening is gauged, the locating device 35 is employed as are the locating angles formed to the left-hand side of members 2t and 21 as shown in Fig. 5.

The construction of both devices 35 and 36 is the same md thus a detailed description of device 35 is believed sufiicient. As shown in Fig. 4, device 35 includes an L- shaped member 42 adapted to be secured to section 11a of member 11 by adjustable means such as a screw member 43. The member 42 is provided with a slot through which a screw 43 extends, and thus the locating end 42a of member 42 may be adjusted relative to section 11a to engage the adjacent portion of the door jamb. A second angle member 44 depends from angle member 42 on a screw member '45, the angle members 42 and 44 being separated a predetermined distance by adjustable means such as a plurality of shim washers 46. The angle member 44 is provided with a locating face 44a, the purpose of which will later be described. By changing the number or thickness of the shim washers 46, the over-all distance between locating surfaces 42a and 44a may be adjusted in predetermined manner.

Continuing now with the description of the operation of the door frame gauge with both T-shaped locating devices 20, 21 against the corner of the jamb, preferably at the right-hand side of the operator, the operator then adjusts the corresponding locating device 36 until its jamb engaging surface 42a is against the side of the jamb and then locks it in position by the locking member 43-. In orderto simplify the use of the gauge by the operator, the operator will apply the gauge to each door frame opening in the same manner. Thus in, the preferred operation of the gauge, it is placed first against the jamb to the rightof the operator and then against the jamb to the left of the operator to complete the gauging operation, regardless of whether the door is a right-hand door or a left-hand door. To enable the operator to remember whether the gauge has been adjusted for the hinge side of the frame or the lock side of the frame, there is provided a member 47 with different indicating means at the opposite ends thereof. Any suitable indicating means may be employed, the one shown in Fig. 4 employing a single projection 47a at one end and double projections 47b at the opposite end. As a door will be provided with more than one hinge but generally only one lock, for convenience the single projection 47a may be designated as the lock indicating means and the double projections 47b may be designated as the hinge indicating means. Thus when the operator gauges the contour of a jamb with either of the locating devices 35 or 36, he will turn the member 47 one way or the other so that the projections adjacent the locating surface 42a will correspond to either the hinge jamb or the lock jamb. As shown in Fig. 4, the indicating means 47 is set for a hinge jamb. The equipment for planing and cutting the doors .0 size is frequently set up in one room of a building, and the operator then takes the adjustable door frame gauge around to the various rooms in the building to gauge each of the door frame openings. By employing indicating means such as shown in Fig. 4, the operator is not required to remember which of the locating devices 35 and 36 was set for a hinge receiving jamb and which for a lock receiving jamb. Thus the chances for errors in the use of the gauge are eliminated.

With the members 20, of the upper and lower T-shaped locating blocks against the jamb at its upper and lower ends, the locating surface 42a will determine where the intermediate point of the jamb is located. These three points 20, 42a, 29 will enable the operator to fit the corresponding edge of the door to the contour of its adjacent jamb. As the steel bucks, when they deviate from the vertical, are either bowed in or out and seldom, if ever, rippled, the three locating points are suflicient to determine the contour of the jamb or steel buck. It is, of course, to be understood that additional sections 11a and additional locating units corresponding to 35 and 36 could be added at any location between the end locating members 20 without departing from the scope of the present invention. The door frame gauge It is adjustable and adapted for use with different sizes of dors, and thus to be sure that the locating devices 35 and 36 do not engage a hinge seat or a lock seat on the door jamb during a gauging operation, the devices 35 and 36 are adjustable lengthwise of member 11 and may be secured to any of the notches in section 11a in suitable manner as by the locking member 43 which is adapted to extend into the threaded openings 48 in each of the notches of section 11a.

After the locating device 36 has been set with respect to the jamb, the gauge 10 is turned over so that the elongated member 11 will be adjacent the left-hand jamb in the door frame and the opposite sides of locating members 20 and 21 will then locate the gauge 10 with respect to that jamb. To gauge the width of the door frame, the micrometer adjusting member 25' at the top of the gauge 10 is adjusted until its outer end engages the opposite jamb from the one which is engaged by the locating members 20. The dimension from the jamb engaging surface of member 25 to the jamb engaging surface 20 at the upper end of member 11 will correspond to the width of the door frame opening at the head end of the door. A similar adjustment is made on adjusting member 25' to gauge the width of the door frame opening at the bottom. The adjusting members 25 and 25' may then be locked in position by means of thumb screws 25a and 25a respectively. To gauge the squared relationship between the side jambs and the head jamb of the door frame, the spring biased plunger 31 is released and moved against the head jamb and then locked in position by thumb screw 33. The locating surface on member 22 which is carried on arm 12 is held against the head jamb of the door frame by the spring biased plunger 39 at the opposite or bottom end of member 11. The spring biased plunger 39 may be locked in position to gauge the over-all length of the door frame opening. However, this is generally not necessary, as when steel bucks are assembled into door frames, the over-all length can be closely controlled, and thus chances for errors in the length or height of the door frames are very small. To gauge the contour of the jamb, the locating surface 42a of the locating device is moved against the adjacent intermediate point of the jamb in manner similar to that previously described in connection with locating device 36, and it is adjusted in the same manner. However, its indicating device 47 will be turned to the opposite end from that of the other device 36. Thus if the indicating member for device 36 were turned to indicate a hinge jamb, the indicating member for device 35 would be turned to indicate a lock jamb.

With the door frame gauge 10 adjusted in the foregoing manner, the operator has now determined all of the measurements necessary for him to prepare an unfinished door so that it will accurately fit the selected door frame. The gauge 19 preferably is first placed on an adjustable saw table and the measured relationship between the side jamb and the head jamb as determined by locating surfaces 20 and 31 transferred thereto. The door may then be cut to the required length with the head end of the door being cut at the same angle as that of the head jamb of the door frame. The gauge 10 is then placed on a novel door sizing supporting device which will now be described.

Referring to Figs. 1 and 2, there is shown a novel door sizing supporting device 50 adapted interchangeably to receive the door frame gauge 10 and a door D to be prepared to the size of the dimensions carried by the gauge 16. The device 50 includes a frame comprising spaced vertical leg members 51, 52 which are adapted to be held in vertical position by means of said members 53 and 54, Fig. 2. A pair of the side members 53 and 54 may be secured at their outer ends to each of leg members 51 and 52 as shown in Fig. 2 in connection with the leg 52. The members 53 and 54 are adapted to be supported at spaced locations from the legs 51 and 52 by any suitable supporting means such, for example, as a work bench or table. While the specific details of construction of the table are not particularly important, it is preferable that the table be constructed for the convenience of the operator as providing a support for his various tools which are to be used during the door sizing operation. Such a table 55 has been illustrated in Figs. 1 and 2. To accommodate doors of different thicknesses between the vertical legs 51 and 52 and the table 55, it is preferable that provision be made for adjustment. For example, one suitable provision for adjustment has been shown in Fig. 2 where members 53 and 54 have been provided with elongated slots having screw members adapted to extend therethrough into table 55. Thus the spacing between the table 55 and the door sizing supporting device 50 may be readily adjusted to accommodate doors or work of different thicknesses. While the member 53 shown in Fig. 2 is straight, the corresponding supporting member 53a, Figs. 1 and 2, shown at the opposite end of device 50 is preferably U-shaped. In this manner the distance between the legs 51 and 52 of the supporting device 50 may be less than the overall length of the door to be placed on the device.

The legs 51 and 52 preferably are formed of angle members, and there is provided a horizontal section 57 forming a supporting section between the two legs 51 and 52. The section 57 also is preferably formed of right-angle members and includes an upper angle member 58 and a lower angle member 59 secured thereto as by riverts or other clamping means 60, Fig. 1A. The aligned vertical faces of angle members 58 and 59 provide the work engaging surface of the section 57 and are adapted to hold the work firmly against the opposed surface of the work table 55. The section 57 is readily removable from the vertical legs 51 and 52. The legs 51 and 52 each are provided at their upper ends with a vertical slot 52a, Fig. IE, to receive the interlocking angle blocks 62 and 64 which are carried undereneath the angle member 58 and at its opposite ends. The interlocking member 62 at the left-hand end of the device 50, as shown in Fig. 1, is similar to member 64 except it additionally includes a section 62a which project outwardly of the plane of the paper as shown in Fig. 1. This section 62a is adapted to be moved toward the left in Fig. 1 until it is in engagement with the adjacent portion 52b of leg 52. This will locate the horizontal section 57 with respect to the vertical legs 51 and 52 and prevent it sliding out of position as the plane passes over it.

An adjustable guide rail 66 is carried by the vertical section of angle member 58, Figs. 1 and 1A. The guide rail 66 is of flexible construction and preferably is formed from a bendable material such as cold rolled steel. The guide rail 66 is secured at its opposite ends to the member 58;however, the intermediate portion of the rail 66 is adapted to be moved vertically with respect to member 58 so' that it may conform with the contour of the jambs. As shown in Fig. 1A, the rail 66 has secured thereto a threaded block 67 which is adapted to receive one end 68a of a threaded member 68. The opposite end 68b of the member 68 is adapted to be received by the threaded opening in a block 70 which is secured to the angle 58. The threads on portions 68a and 68b are of the opposite hand, and. thus when member 68 is rotated in one direction, the blocks 67 and 70 will tend to be pulled together, thus lowering the upper edge of rail 66 with respect to the member 58. When the threaded member 68 is rotated in the opposite direction, the blocks 67 and 70 will tend to spread apart, thus raising the upper surface of guide rail 66 with respect to member 58. The guide rail 66 may be provided with slots at locations along its length between its ends, and there may be provided threaded members 69 adapted to extend through these slots and into the vertical section of angle 58. The threaded members ordinarily will be loosened when the adjustment is made of adjustment screw 68, and after the adjustment is completed, the threaded members may be tightened to lock the various portions of the guide rail 66 to the vertical portion of angle member 58. As the guide rail 66 is formed from a flexible material, it is also possible to raise or lower difierent portions of the guide rail with respect to the supporting member 58 should such adjustment be desirable or necessary in some applications. From this description it will be apparent that such other portions of the guiderail 66 may be adjusted by hand independ ently of the central portion adjacent the adjusting member 68. The adjusting can also be accomplished with wedges, eccentrics, etc.

To support the work, whether it be the door frame gauge or a door, on the device 50, each of the legs 51 and 52 is provided with an adjustable platform or support. The adjustable support 75, Figs. 1 and 2, may be attached to the leg 52 by suitable means such, for example, as a threaded clamping member or knob 76 which is adapted to have an end extend through one of the openings in the leg 52 and into the body portion of the support 75. The body member of support 75 includes a vertical section which has a thickness corresponding to the thickness of the vertical portions of angles 58 and 59, and thus is adapted to cooperate with these portions to hold the work in a vertical plane between the legs 51, 52 of device 59 and the opposed vertical face of table 55. The body portion of the support 75 also includes a locating element adapted to engage the side of the leg 52 and a horizontal section which is provided with a horizontal pad 77 adjustable in elevation. Such'adjustment'rnay be provided in any suitable manner such, for example, as by the use of shim washers, or spring loaded as shown in Fig. 8, or as shown in Fig. 2, the adjustment may be provided by means of a threaded member 78 which is between spaced guide pins which depend from pad 77 and is adapted threadedly to engage the horizontal body portion of support 75. The leg 51 has a similar support 75 with corresponding parts 76', 77' and 78'.

The adjustable door frame gauge 10 is provided with hangers 80 and 81 on opposite sides and at each end of the gauage. The hangers 80 and 81 are adapted to overlie the guide rail 66 and thus are preferably L-shaped, as shown in Fig. 2. It will be noted that the undersides of L-shaped members and 81 are of difierent depths. This may be accomplished in any suitable manner and has been illustrated in Fig. 2 by applying a greater number or thickness of shim washers 83' to the underside of member 81 than of washers 83 to the underside of member 80. The shim washers 83 and 83' are used to control the amount of material to be planed from the door.

The gauge it) is placed on the sizing device 5% with the arm 12 of the gauge adjacent the leg 52 and with hangers 80 overlying the guide rail 66. The support 75 on leg 52 is adjusted vertically until the horizontal member '77 engages the outer end of member 25 on the gauge 19. A similar adjustment is made of a like adjustable support 75 carried by leg 51. For large adjustments in supports 75 and 75' the supports may be moved from one hole to another on the corresponding legs 52 and 51, and small adjustments may be provided by moving the member 77 without moving the body members of the supports such, for example, as by rotating the knob 78 shown in Fig. 2. The guide rail 66 is adjusted by member 68 until the surface 44a, Fig. 4, of adjustable device 36 is in engagement with the upper edge of guide rail 66. The over-all dimension x, Fig. 3, between the surface 44a and the surface 42:: of device 36 is the same as the over-all dimension x, Fig. 5, between the upper surface of member 28 on gauge 10 and the outer surface of the outer shim washer 83 carried by members 86, Fig. 2.

The gauge 10 is then removed from the sizing device 50 and a door D is inserted in its place, as shown in Fig. 6. A plane 85 is then placed on the upper edge of the door, as shown in Fig. 6. The plane may be of any suitable type; however, in interests of speed the plane is preferably electrically operated, as is the case of plane 85. Attached to the body portion of plane 35 is a metal plate 86, Figs. 23-10, which is adapted to extend below the plane 85. The plate 86 may be attached to the body of plane 85 in any suitable manner as by the hinge 88. The details of the plane 85, the plate 86 and the hinge 88 by themselves form no part of the present invention. However, such elements do form part of my new and improved combination now to be described. A guide member 87 is attached to the body portion of plane 85 and extends therebelow to cooperate in spaced relation with plate 86 and together thus serve as side supports or guides for the plane. To provide additional rigidity for the hinged plate 86 there is preferably provided a bracket 89 one end of which is secured to plate 86 and the other end being provided with an opening so that it may be carried by the threaded rod of front handle of knob 90 of the plane. To enable the plate 86 to function as a limit gauge as well as a guide during a cutting operation, as later to be described, the bottom of plate 86 is provided with shoe means 91 which is adapted to engage the upper surface of guide rail 66 as shown in Fig. 6. The shoe 91 may be attached to plate 86 in any suitable manner such, for example, as by screws, Fig. 10. The shoe 91 may be constructed from any suitable material, such, for example, as brass; and to enable it to slide freely along the guide rail 66, there is preferably provided lubricating means such, for example, as the passages 92 which extend through the guide shoe 9i and are packed with lubricating absorbing material 33, such, for example, as felt. Thus a lubricating liquid may be applied to the felt within the holes 92, and the felt will in turn apply the lubricating liquid to the guide rail 66.

The guide 86 is disposed in a predetermined angular position relative to the bottom of the plane 85. it is common practice today to provide wooden doors either with square edges or beveled edges as pointed out in my co-pending application Serial No. 455,890, issued Aug. 6, 1957 as US. Letters Patent 2,801,655. if the edges of the door are to be square the guide 86 is set in a position at right angles to the plane 85. If the edges of the door are to be beveled the guide 86 will be set and locked at an angle to provide the normal bevel for planing a door which is approximately ,4 inch to an inch of thickness of the door. The other guide 87 is disposed in a spaced plane parallel to that of guide 86. This will enable the plane to produce the edge as required.

To adapt the plane for use on Work of different width such as doors of different thicknesses, the guide 87, Figs. 8, 9 and 11, is supported by the body portion of the plane 85 but is adjustable in relation thereto. As shown in Figs. 9 and 11, a rod member 95 is adapted to have one of its ends threaded and screwed into the body portion of plane 85. The outer end of rod 95 is adapted to carry an adjustable block 96 which may be adjusted lengthwise of rod 95 and locked in any desired position thereon by means of a locking member 97. The lower end of block 96 supports an angle member 98 which is adapted to extend beneath the plane body in an angular position parallel to the guide 86. The member 93 may be provided with a facing member 99 of any suitable material such, for example, as pressed wood, which will slide along the work without scarring it during a planing operation. The motor for driving the rotary cutter of the electric plane 85 may be operated by actuating the switch 100 carried by the handle 191, Fig. 8. The member 98 is provided with a groove 98 to avoid any interference with the cutter.

With the spacing between the guides 86 and 87 ad justed to the thickness of the work but not so closely as to prevent the plane from being moved lengthwise of the work, the plane is moved from right to left, as shown in Fig. 6, a sufiicient number of times until the shoe 91 rides on the upper surface of guide rail 66. This spacing will control the bevel accurately for a less skilled operator. As the guide rail 66 has previously been adjusted to correspond to the contour of one of the side jambs of the door, the plane 85 will in turn shape that edge of the door in accordance with the measured contour of the jamb. When the shoe 91 rides on the rail 66, further downward movement of the plane 85 will be limited and the plane will no longer cut any material from the door.

The door is then removed from the sizing device 50, and the gauge it is again placed in position thereon, this time with the gauge turned end for end so that the washers 83' of hangers 81 are in engagement with the top of rail 66. It will be recalled that there are a greater number or thickness of washers 83 under hangers 81 than under hangers 80. Thus the gauge 10 projects a greater distance above the rail 66 and it will now be necessary to raise the platforms 77, 77' of supporting devices 75, 75' until they engage the outer ends of members 25 and 25'. The distance the platforms are raised corresponds to the difference in the distance x, Fig. 5, from the outermost shim washer 83 under hanger 80 and surface 20 and the distance y, Fig. 5, from the outermost shim washer 83 under hanger 81 and surface 20. In other Words, it corresponds to the difference in the thicknesses of the stacks of shim Washers 83 and 83' under hangers 80 and 81, for example in the order of inch.

The purpose of the foregoing will now be apparent. Fewer shim washers are used under hangers 80 in order that the distance between the guide rail 66 and the support platforms 77, 77 will be increased; and thus, when the door is planed to the contour of the first jamb, the Width of the door will still be oversize and there will still be material on the other edge of the door for a second planing operation. The shim washers 83 under hangers 81 are adjusted to insure that the spacing between the door supporting platforms 77, 77' and guide rail 66 will be decreased for the second planing operation and will bring the door to the required Width as determined by the gauge 10. Such required width for the door will correspond to the measured width of the door frame opening (the over-all distance between surfaces 20 and the ends of members 25, 25) less the selected amount of clearance k that is desired between the door and frame when the door is hung. The guide rail 66 is then adjusted in accordance with the locating device 35 in manner similar to that previously described in connection with locating device 36. It is to be noted that the over-all dimension of device 35 is equal to distance y, Fig. 3, and this is the distance that the jamb engaging surfaces of gauge 10 project above the guide rail 66.

With the sizing device 50 adjusted in the foregoing manner, the gauge 10 is then removed from the sizing device and replaced by the door, as in Fig. 6. This time the door is turned end for end and the opposite edge of the door is turned up for planing. The finished edge of the door is placed on the supports 77, 77. The plane 35 is again placed on the upper edge of the door, and it is moved lengthwise of the door from right to left until the shoe 91 again engages the upper surface of guide rail 66. As may be seen in Fig. 9 the distance between the cutter of the plane and the bottom of shoe 91 is equal to the distance y minus twice the clearance k at each side or the door or (y-Zk). Thus when shoe 91 engages rail 66 both edges of the door will have been planed to fit the contour of the side jambs of the door frame as determined by the adjustable door frame gauge 10 with a uniform clearance k between each side jamb and its respective edge of the door. The finished width of the door Will be equal to the Width of the door frame opening less the combined side clearances 2k.

From the foregoing description it will be seen that the door frame gauge 10 is adjustable to gauge frames of different width as well as different height. With doors of difierent Width the over-all length of the arms 12 and 13 from locating surfaces 20 to the outer ends of members 25 and 25 will be changed and thus a corresponding change will be made when the gauge 10 is placed on the door sizing device 50 and the dimensions of the door frame are transferred from the gauge 10 to the device 59. The device 50 is adjusted by raising or lowering the supporting platforms 77 and 77' as required. The dimensions x and y, Figs. 3 and 5, on the gauge 10 need not be changed when changing from one size door frame to another. If the clearance k at each side of the door is to be changed this may be accomplished by raising or lowering the cutter of the plane to vary the distance indicated as y-Zk in the required direction. Thus by lowering the cutter the distance (y2k) between the cutter and the bottom of shoe 91 Will be decreased and more material will be cut from the edge of the door thus increasing the clearance between the door and the jamb.

It will be noted from the foregoing description of the sizing device 5!) that the bar or section 57 for supporting the gauge 10 and for holding the door in place on the device 50 is readily removable. All that is necessary is to lift the section 57 upwardly to disengage the members 62 and 64 from the vertical slots such as 52a, Fig. 1B in their respective legs 52 and 51. The legs are ad justed relative to the table 55 by slotted members 54 and 53 so that the spacing between the vertical face of section 57 and the opposed vertical face of table 55 is slightly larger than the thickness of the door to be received therebetween. Thus when a door is in place on the supporting platform 77, Figs. 2 and 6, the section 57 may be easily inserted in place and at the same time the section will hold the door against the table 55 but without the need of additional clamping means. The doors tend to bow a slight amount from end to end and there is sufiicient friction gripping created by the vertical face of section 57 and the opposed face of table 55 to prevent the door from slipping during the planing and other operations performed on it. Thus construction of the device 50 by eliminating the need for additional clamping means saves a substantial amount of time during the insertion and withdrawal of the door from the device 50 and thus saves a substantial amount of time in the over-all operation.

Further in the interests of saving time, it is preferable to perform all of the operations on the first door edge after its planing operation has been completed and before the door is turned over for the second planing operation on the opposite edge of the door. Accordingly, if the first edge of the door is the hinge receiving edge, the template assemblies for use in cutting the hinge seats in the door are disposed along the door edge and adjusted to their required locations.

To accomplish this, there is provided a hinge locating gauge 1111, Figs. 12-14, which is adapted to gauge the location of the pre-cut hinge recesses in the jamb or steel bucks and then to locate the template assemblies lengthwise of the door edge preparatory to cutting or routing hinge seats in the door. The gauge 110 preferably includes a frame member 111 which may be adjustable as to over-all length by including a plurality of sections slidable relative to each other and adapted to be locked together at the selected length as by bolts 169. At the left-hand end of the gauge, as shown in Figs. 12 and 13, there is provided a rotatable locating arm 112 which is adapted to be held on the frame 111 as by an adjustable member such, for example, as a screw member 113. The outer end of member 113 is adapted to engage the head jamb HI, Fig. 14, and the spacing between the outer end of member 113 and the surface 114 on arm 112. is adapted to be adjusted in accordance with the clearance desired between the head jamb and the head end of the door. This may be accomplished in any suitable manner and may include the use of shim washers 115, as shown in Fig. 13.

At the opposite or bottom end of gauge 110 there is provided a telescoping member 117 which is a spring loaded plunger having a foot 118 adapted to be positioned on the floor beneath the head jamb in the door frame opening. A pin 130 extends across the interior of a tubular section of frame 111 and forms an abutment for one end of a compression spring 131 the opposite end of which engages the inner end of plunger 117. A bolt 132 extends through a slot 133 in frame 111 and a slot 134 in the plunger 117 spaced a short distance from its inner end. When pressure is applied to foot 118 member 117 slides into frame 111 resisted by spring 131 and bolt 132 prevents member 117 from being pushed out of frame 111 when there is no pressure on foot 118. Foot 118 is adjustable in member 117 and is clamped by a screw 135. This adustment permits additional variations in length of the gauge 110 and enables a steady pressure to be maintained on spring 131. The spring loaded plunger 117 will hold the outer end of member 113 against the head jamb, and while the gauge 110 is in this position, the

plates 120 may be adjusted lengthwise of the frame 111 until they are in alinement with the pre-cut hinge openings in the steel buck. The plate members 120 need not be as wide as the hinge openings in the steel buck, and all that is necessary is that the edges 120a of the plates be adjusted toward the arm 112 until the edges 120a are in engagement with the upper edges of each of the respec tive hinge receiving openings h in the steel buck J. The respective plates 120 are then locked in these positions as by members 122, and the gauge 110 is removed from the door frame opening.

The gauge 110 is then placed on top of the hinge receiving edge of the door, as shown in Fig. 13, with surface 114- in engagement with the head end of the door. Suitable template assemblies 125, one being shown in Fig. 13, for example, as of the type shown in Patent No. 2,605,791 or in my Patent No. 2,801,655, may be placed on the upper edge of the door and moved lengthwise of the door until the edges 126a toward the head end of the door of the templates 126 in the respective assemblies engage the corresponding edges 120a of plates 12%. It is not necessary that the length of the plates 120 be as great as the length of binge seats or the opening in the template 126. The various template assemblies may then be clamped to the door and the gauge 110 removed. The

hinge seats may then be routed in the edge of the door in the manner described in my aforesaid patent and application. The template assemblies 125 may be disposed individually on the edge of the door, or they may be carried by a common frame and adjustable therealong relative to each other; the latter arrangement permits the location of the template assemblies to be accomplished in somewhat less time.

After the door is turned over and the second planing operation completed, the lock may then be installed in that edge of the door. A suitable device for locating and cutting the lock receiving opening in the door is disclosed in my aforesaid patents.

As pointed out above, the supporting platforms 75, 75' may take various forms. A preferred embodiment is illustrated in Fig. 7 where the support 150 comprises an L-shaped body member 151 adapted to be attached to legs 51 and 52 of the sizing device 50 by a clamping member 152. The back of member 151 as shown in Fig. 7 is provided with a vertical shoulder member that extends throughout the length of member 151. This shoulder is adapted to engage the side of the legs and cooperate with clamping member 152 to hold the support 150 V in alignment similar to the construction previously described in connection with supports and 75'. The support 151} includes a horizontal plate 153 which is carried by a spring biased plunger 154 with the plate 153 being biased upwardly, as shown in Fig. 7, by a spring 155. To limit the upward movement of plunger 154 its lower end which is adapted to protrude from beneath member 151 may be provided with a stop washer secured thereto as by a screw. When the plate 153 has been lowered to the required location against the bias of spring 155 by the members 25 and 25 on gauge 10, the plate 153 may then be locked in position by suitable means such, for example, as the locking member 157 disposed within the body member 151 and adapted to have its curved portion 157a held tightly against the plunger 154 by means of a threaded clamping member 158. This device 151) permits the supporting plate 153 to be moved to the required position merely by the weight of the gauge 10 and then locked in that position so that it will support the door at the required position relative to guide rail 66 during the planing operations. The ease of operation of the device contributes substantially to the saving of time during the door sizing operations described above.

The novel door sizing hanging and locking system and components thereof as described herein provide a substantial decrease in the time normally required to prepare a door for hanging. At the same time it insures that the door will fit properly when it is hung, and eliminates the numerous cut and try operations involved when a door is hung by hand without the benefit of applicants invention. Furthermore, it insures that the door will have uniform clearance around its edges with respect to the frame when the door is installed, and this is accomplished without the door ever having been previously placed in that frame.

The term door as'used throughout the specification and claims is intended to be generic and to encompass other similar work to which like sizing operations and devices disclosed herein are applicable.

While there has been described a preferred embodiment of the invention, it will be understood that further modifications may be made without departing from the spirit and scope of the invention as set forth in the appended claims.

What is claimed is:

1. A gauge for measuring the width and contour of a pro-installed door frame preparatory to hanging a door therein comprising an elongated member, a pair of spaced arms carried by said elongated member adjacent the ends thereof and projecting from one side thereof, said arms being parallel to each other and perpendicular to said elongated member, stationary locating means carried at each end of said elongated member on the opposite side thereof from said pair of arms and adapted to engage a side of the door frame, means for adjusting the length of each of said arms into engagement with the opposite side of the door frame for gauging the width of said frame at the top and bottom thereof, and adjustable locating means carried by said elongated member intermediate the ends thereof and projecting from the same side thereof as said stationary locating means for selective engagement with the same side of the door frame as said stationary locating means in cooperation therewith to gauge the contour of said side of the door frame, said adjustable locating means comprising an intermediate arm substantially shorter in length than either arm of said pair of arms.

2. A gauge for measuring the width and contour of a pre-installed door frame according to claim 1 wherein said stationary locating means comprises a pair of T- shaped locating blocks respectively disposed adjacent the ends of said elongated member, said T-shaped blocks including members disposed at right angles to each other to form the stem and cross bar of the T, said cross bars of said member blocks being adapted to be placed against the side of a side jamb respectively adjacent the top and bottom of the door frame and said stems of said blocks being adapted to be positioned adjacent the edge of said jamb at corresponding locations, the T-shape of said blocks permitting said gauge to be reversed within the door frame to enable both side jambs of the door frame to be gauged with the same elongated member.

3. A gauge for measuring the width and contour of a pre-installed door frame according to claim 1 wherein said means for adjusting the length of each of said arms comprises an adjustable member, and supporting means for interconnecting one of said adjustable members and said elongated member to maintain the perpendicular relationship between said adjustable member of said arm and said elongated member.

4. A gauge for measuring the width and contour of a pre-installed door frame according to claim 3 wherein said supporting means includes an adjustable member for varying the overall length of said supporting means in accordance with the extension of said adjustable member carried by said arm.

5. A gauge for measuring the Width and contour of a pre-installed door frame according to claim 1 wherein said adjustable means for said pair of arms includes micrometer adjustment structure for small variations in overall length of said arms.

6. A gauge for measuring the width and contour of a pre-installed door frame according to claim 1 wherein the end of said elongated member to be placed at the top end of the door frame is provided with stationary end locating means for engaging the head jamb of the door frame, and the adjustable means of one of said arms is provided with an adjustable locating member which is perpendicular to said arm and parallel to said elongated member and is adapted to cooperate with said stationary and locating means to gauge the squareness at the top of the door frame.

7. A gauge for measuring the width and contour of a pre-installed door frame according to claim 6 wherein said last-named adjustable means includes spring biasing structure for forcing said means against the head jamb of the door frame, and means for locking said adjustable means in fixed position.

8. A gauge for measuring the width and contour of a pre-installed door frame according to claim 1 including a spring loaded extension carried at one end of said elongated member, said extension being adapted tohold the locating members of said gauge in engagement with the door frame during a gauging operation.

9. A gauge for measuring the width and contour of a pre-installed door frame according to claim 1 wherein 14 said adjustable locating means includes a second intermediate arm carried by said elongated member intermediate the ends thereof and adapted to cooperate with said stationary locating means for gauging the contour of the other side of the door frame.

10. A system for hanging a door in a door frame comprising an adjustable gauge having a plurality of spaced locating projections for measuring the width and contour of the door-receiving opening in the frame and maintaining the measured relationship, at least three of said spaced locating projections being disposed along one side of said adjustable gauge to measure the contour of a side of the door frame, an adjustable supporting device having means for first receiving and supporting said adjustable gauge and then the door, said supporting device having means adjustable in accordance with the width and contour of the door-receiving opening as determined by said adjustable gauge while supported thereon, and said last-named means on said supporting device having a surface deformable in accordance with the alignment of said three spaced locating projections for guiding a cutting tool along an edge of the door while held by said supporting device to decrease the width of the door and change its contour by an amount predetermined by said adjustable gauge.

11. A system according to claim 10 wherein the door frame is provided with pre-cut hinge recesses, including means adjustable to the locations of the pre-cut hinge recesses comprising frame means, locating members carried by said frame means and adjustable relative to each other to positions corresponding to the spacing of the precut hinge recesses in the door frame, and means on said frame means for locating said frame means relative to one end of the door, said locating members on said frame means being adapted to engage template means along the hinge receiving edge of the door for locating the template means in proper relation to the door preparatory to cutting hinge recesses in the door.

12. In a door-hanging system the sub-combination comprising frame means adjustable as to a length somewhat greater than the height of a door frame, a spring-loaded extension carried at the bottom end of said frame means for engaging the floor at the bottom of the door frame, a locating member carried at the opposite end of said frame means for engaging the head jambof the door frame to increase the loading pressure on the spring, and at least one locating member carried intermediate the ends of said frame means, said spring-loaded extension being adapted to hold said frame means and said locating members in predetermined positions within the door frame relative to the jambs during an operation in said doorhanging system.

13. A gauge for measuring the width and contour of a pre-installed door frame preparatory to hanging a door therein, the door frame being of the type including a head jamb and side jambs, comprising an elongated member, a pair of spaced arms carried by said elongated member adjacent the opposite ends thereof, said arms being parallel to each other and perpendicular to said elongated member, said arms each having a free end and a separate locating projection disposed thereon, individual stationary locating means carried by and projecting from the side of said elongated member adjacent each end, said locating means including members disposed at right angles to each other, one of said members being adapted to be placed against the side of a side jamb adjacent the top and bottom of the door frame for cooperation with the respective locating projections at the free ends of said pair of arms to gauge the width of said frame at the top and bottom thereof, the other of said members being adapted to be placed against the edge of the side jamb at corresponding locations to control the position of said gauge within the door frame, and individual adjustable locating means carried by said elongated member intermediate the ends thereof, said adjustable locating means sides of said elongated member for cooperation with said stationary locating means and said locating projections in determining the contour of the side jambs of the door frame.

14. A door-sizing device comprising vertical supporting means for holding a door in vertical position on one of its side edges with its other side edge up and exposed horizontally preparatory to removing material from the exposed edge thereof, a rigid horizontal member carried by said vertical supporting means, said horizontal member having at the opposite ends thereof interlocking structure adapted to be removably received by the upper ends of said vertical supporting means, said horizontal member being removable from said vertical supporting means by vertical movement without interfering with the vertical support of the door to facilitate insertion and removal of the U001 with respect to said sizing device, a guide rail carried by said rigid horizontal member and adapted to be disposed along the exposed edge of the door for controlling the amount of material to be removed from the door edge by a cutting tool, said guide rail having the characteristic of being deformable to change the contour of its guiding surface in manner predetermined by the contour of the jamb for the door, and means for locking said guide rail to said rigid horizontal member after deformation whereby the" door edge when cut to size will have a contour corresponding to the contour of the jamb.

15. In a system for planing the side edges of doors to a predetermined shape, the improvement of a door-sizing device which comprises rigid elongated structure, deformable elongated structure carried by said rigid elongated structure, means for horizontally supporting both of said elongated structures adjacent a door to be planed, both of said elongated structures having a length corresponding to that of a side edge of the door to be planed, said deformable elongated structure having -a guide surface for a plane adjustable between the ends thereof to conform with a predetermined shape, the ends of said deformable elongated structure being fixed to the corresponding ends of said rigid elongated structure with said guide surface projecting above said rigid elongated structure through a length corresponding to that of the side edge of the door, door supporting structure carried by said supporting means for said elongated structures, said door-supporting structure being disposed below and in spaced relation to said guide surface on said deformable elongated structure for supporting a door vertically edgewise in side-edge-up position with one of the side edges of the door on said door-supporting structure and the other side edge of the door adjacent and extending along said horizontally-supported elongated structures, means for adjusting the spacing between said doorsupporting structure and the fixed ends of said guide surface to adjust the position of the door relative to said guide surface, and adjustable means connected to said elongated structures intermediate the ends thereof, said adjustable means being movable to bend said deformable elongated structure intermediate its ends relative to said rigid elongated structure and thus change the shape of said guide surface in manner predetermined by the contour of the jamb for the door whereby the door edge 16 when planed to size as controlled by said guide surface will have a contour corresponding to the contour of the jamb.

16. In a system according to claim 15, wherein said door supporting structure is adjustable in elevation by rotatable means. 7

17. In a system according to claim 15, wherein said supporting structure is spring biased in a vertical direction toward said guide surface for adjustment of the spacing therebetween in predetermined manner, and means for locking said supporting structure in fixed position after adjustment to maintain the predetermined spacing between said guide surface and said supporting structure.

18. In a system for hanging a door in a door frame, the method comprising gauging the midpoint of a side jamb relative to the ends of the jamb, gauging the midpoint of the other side jamb relative to the ends of the other side jamb, gauging the width of the frame opening at the top and the bottom to measure the width and contour of the door-receiving opening in the frame, supporting a door on one of its side edges with the other side edge disposed upwardly, supporting an elongated de formable member adjacent the exposed edge of the door, transferring the gauged contour of one of the side jambs to the deformable member by bending the deformable member at the midpoint thereof so that the resulting contour of the deformable member will correspond to the gauged contour of one of the side jambs, moving a cutting tool along the deformable member to cut the exposed edge of the door so that it has a contour corresponding to the gauged contour of one of the side jambs, reversing the position of the door so that the opposite side edge thereof is exposed along the deformable member, transferring the gauged contour of the other side jamb to the deformable member by bending the midpoint of the deformable member so that the resulting contour of the deformable member corresponds to the gauged contour of the other side jamb, and moving the cutting tool along the deformable member to cut material from the last-named exposed edge of the door so that it will have a contour corresponding to the gauged contour of the other side jamb of the door frame.

References Cited in the file of this patent UNITED STATES PATENTS 773,176 Washington Oct. 25, 1904 969,298 Pfefierkorn Sept. 6, 1910 1,101,516 Ahlvin June 30, 1914 1,529,273 Potter Mar. 10, 1925 1,641,645 Skolnik Sept. 6, 1927 1,642,474 Willoughby Sept. 13, 1927 1,812,755 Quinsler June 30, 1931 2,356,923 Firstone Aug. 29, 1944 2,400,862 Zern May 21, 1946 2,605,790 Schwarzer Aug. 5, 1952 2,605,791 Zern Aug. 5, 1952 2,636,282 Krouquist Aug. 28, 1953 2,664,122 Allen Dec. 29, 1953 2,679,696 Reeder June 1, 1954 2,684,090 Bernitz July 20, 1954 2,733,744 Stanton Feb. 7, 1956 

